Voltage conversion module and bobbin

ABSTRACT

The present disclosure is related to a voltage conversion module which includes a front side magneto-sensitive unit, at least one voltage conversion unit, a core group, and a bobbin. The bobbin includes a first accommodating part, a second accommodating part, and a through hole. The first accommodating part is used for accommodating the front side magneto-sensitive unit. The second accommodating part is used for accommodating the at least one voltage conversion unit. The through hole is used for accommodating the core group. The second accommodating part includes first and second openings. The first opening is disposed at one side of the second accommodating part. The second opening is disposed at another side of the second accommodating part. The first and second openings are disposed opposite to each other, and a heat dissipation channel is formed between the first opening, the second opening and the at least one voltage conversion unit.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. application Ser. No.15/704,007, filed Sep. 14, 2017, which is a reissue application of U.S.Pat. No. 9,559,609 B2, issued Jan. 31, 2017, which are hereinincorporated by reference in their entireties. This application is acontinuation-in-part of U.S. application Ser. No. 15/073,319, filed Mar.17, 2016, which claims priority to Taiwan Application Serial Number104133388, filed Oct. 12, 2015, which are herein incorporated byreference in their entireties. This application claims priority toProvisional Application No. 62/466,383, filed Mar. 3, 2017, which isincorporated by reference herein in its entirety. The presentapplication is a continuation application of U.S. application Ser. No.15/706,785, filed Sep. 18, 2017, which is herein incorporated byreference. All of these applications are incorporated herein byreference.

BACKGROUND Field of Invention

The present invention relates to power conversion systems.

Description of Related Art

Since diode and Schottky diode have designated forward bias, the powerloss of the power conversion system having the diode or Schottky diodeto rectify power is large. Metal-oxide-semiconductor field-effecttransistor (MOSFET) has advantages of low input resistance, shortresponse time, and high input resistance, thus it replaces the diode andSchottky diode to be the main component of the rectifier.

In general, the power conversion system includes a plurality ofsynchronous rectifiers, which are driven at the same time the rectifypower entering thereto. Specifically, when an electronic deviceelectrically connected to the power conversion system is activated, thesynchronous rectifiers perform synchronous rectifying procedure, and theMOSFETs of the synchronous rectifiers are switched to rectify the powerentering the synchronous rectifiers; however, when the electronic deviceis inactivated, the synchronous rectifiers does not perform synchronousrectifying procedure. Even if the operation manner of the synchronousrectifier mentioned above is easy, the power provides by the powerconversion system is a constant no matter the electronic device duringnon-light load condition and light load condition, thus the power lossduring the electronic device under light load condition is large.

SUMMARY

An embodiment of the present disclosure is related to a voltageconversion module. The voltage conversion module comprises a front sidemagneto-sensitive unit, at least one voltage conversion unit, a coregroup, and a bobbin. The bobbin comprises a first accommodating part, asecond accommodating part, and a gap. The first accommodating part isused for accommodating the front side magneto-sensitive unit. The secondaccommodating part is used for accommodating the at least one voltageconversion unit. The gap is used for accommodating the core group. Thesecond accommodating part comprises a first opening and a secondopening. The first opening is disposed at one side of the secondaccommodating part. The second opening is disposed at another side ofthe second accommodating part. The first opening and the second openingare disposed opposite to each other, and the first opening, the secondopening and the at least one voltage conversion unit form a heatdissipation channel.

Another embodiment of the present disclosure is related to a voltageconversion module. The voltage conversion module comprises a front sidemagneto-sensitive unit, a voltage conversion unit, a core group, and abobbin. The voltage conversion unit has a circuit board having a baseportion and an expending portion connected to the base portion, arectifier, and a filter. A penetrating hole is formed on the expendingportion, and a magnetic sensitive layer is disposed on the expendingportion for interacting with the front side magneto-sensitive unit. Therectifier is disposed on the base portion. The filter is disposed on thebase portion, wherein the filter and the rectifier are electricallyconnected. The bobbin comprises an accommodating part, a spacer, and athrough channel. The accommodating part comprises a first opening, and asecond opening. The first opening is disposed at one side of theaccommodating part. The second opening is disposed at another side ofthe accommodating part. A winding part is formed between the spacer andthe accommodating part. The through channel penetrates the accommodatingpart and the spacer. Part of the core group penetrates the throughchannel and the penetrating hole.

Still another embodiment of the present disclosure is related to abobbin. The bobbin comprises an accommodating part, a spacer, and athrough channel. The first opening is disposed at one side of theaccommodating part. The second opening is disposed at another side ofthe accommodating part. A winding part is formed between the spacer andthe accommodating part. The through channel penetrates the accommodatingpart and the spacer. The first opening and the second opening aredisposed opposite to each other, and the first opening, the secondopening and an inner wall of the accommodating part form a heatdissipation channel.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention can be more fully understood by reading the followingdetailed description of the embodiment, with reference made to theaccompanying drawings as follows:

FIG. 1 is a circuit block diagram of a power conversion system accordingto a first embodiment of the present disclosure;

FIG. 2 is a circuit diagram of the power conversion system according tothe first embodiment of the present disclosure;

FIG. 3 is a timing chart indicating the operations of power switches andrectifying switches shown in FIG. 2;

FIGS. 4a and 4b are timing charts indicating operations of the powerconversion system during light load condition;

FIGS. 5a and 5b are timing charts indicating operations of the powerconversion system during normal load condition;

FIGS. 6a and 6b are timing charts indicating operations of the powerconversion system during heavy load condition;

FIG. 7 is a cross sectional view of an isolating transformer accordingto the first embodiment of the present disclosure;

FIG. 8 is a diagram showing the state of leakage inductance, themagnetic flux, and temperature distribution in the isolating transformershown in the FIG. 7;

FIG. 9 is a diagram showing the state of leakage inductance, themagnetic flux, and temperature distribution in the isolating transformershown in the FIG. 7;

FIG. 10 is a diagram showing the state of leakage inductance, themagnetic flux, and temperature distribution in the isolating transformershown in the FIG. 7;

FIG. 11 is a circuit diagram of a power conversion system according to asecond embodiment of the present disclosure;

FIG. 12 is a circuit diagram of an integrated power-converting moduleaccording to the present invention;

FIG. 13 is an exploded view of the integrated power-converting moduleaccording to the present invention;

FIG. 14 is a partially assembled view of the integrated power-convertingmodule according to the present invention;

FIG. 15 is an assembled view of the integrated power-converting moduleaccording to the present invention;

FIG. 16 is a sectional view of the integrated power-converting modulealong line 16-16 shown in FIG. 14;

FIG. 17 is a sectional view of the integrated power-converting modulealong line 17-17 shown in FIG. 14;

FIG. 18 to FIG. 29 illustrate a power conversion system according to oneembodiment of the present invention;

FIG. 30 to FIG. 36 illustrate a voltage conversion module according toanother embodiment of the present invention; and

FIG. 37 to FIG. 43 illustrate a voltage conversion module according toyet another embodiment of the present invention.

DETAILED DESCRIPTION

Reference will now be made in detail to the present embodiments of theinvention, examples of which are illustrated in the accompanyingdrawings. Wherever possible, the same reference numbers are used in thedrawings and the description to refer to the same or like parts.

As used in the description herein and throughout the claims that follow,the meaning of “a”, “an”, and “the” includes reference to the pluralunless the context clearly dictates otherwise. Also, as used in thedescription herein and throughout the claims that follow, the terms“comprise or comprising”, “include or including”, “have or having”,“contain or containing” and the like are to be understood to beopen-ended, i.e., to mean including but not limited to. As used in thedescription herein and throughout the claims that follow, the meaning of“in” includes “in” and “on” unless the context clearly dictatesotherwise.

It will be understood that, although the terms first, second, etc. maybe used herein to describe various elements, these elements should notbe limited by these terms. These terms are only used to distinguish oneelement from another. For example, a first element could be termed asecond element, and, similarly, a second element could be termed a firstelement, without departing from the scope of the embodiments. As usedherein, the term “and/or” includes any and all combinations of one ormore of the associated listed items.

It will be understood that when an element is referred to as being“connected” or “coupled” to another element, it can be directlyconnected or coupled to the other element or intervening elements may bepresent. In contrast, when an element is referred to as being “directlyconnected” or “directly coupled” to another element, there are nointervening elements present.

Unless otherwise defined, all terms (including technical and scientificterms) used herein have the same meaning as commonly understood by oneof ordinary skill in the art to which example embodiments belong. Itwill be further understood that terms, such as those defined in commonlyused dictionaries, should be interpreted as having a meaning that isconsistent with their meaning in the context of the relevant art andwill not be interpreted in an idealized or overly formal sense unlessexpressly so defined herein.

Reference is made to FIG. 1, which is a circuit block diagram of a powerconversion system according to a first embodiment of the presentdisclosure. In FIG. 1, the power conversion system (its referencenumeral is omitted) receives an input voltage Vi and is configured toprovide an output voltages Vo. The power conversion system includes aprimary side and a secondary side, which are separated by an isolatingtransformer 30. The isolating transformer 30 includes a primary winding310 and a plurality of secondary windings 320 a ^(˜) 320 d magneticallycoupled to the primary winding 310. The power conversion system furtherincludes a switching module 10, a resonant module 20, anoutput-controlling device 40, and a current sense unit 50. The switchingmodule 10, the resonant module 20, and the primary winding 310 arearranged at the primary side of the power conversion system, and thesecondary windings 320 a ^(˜) 320 d, the output-controlling device 40,and the current sense unit 50 are arranged at the secondary side of thepower conversion system. The output-controlling device 40 includes aplurality of output-controlling modules 400 a ^(˜) 400 d, and thecontrolling modules 400 a ^(˜) 400 d include a plurality of synchronousrectifying units (details are described in the following paragraphs) anda plurality of output switches (details are described in the followingparagraphs). The current sense unit 50 senses a current flowing througha sensing resistor Rs electrically connected to the output-controllingunit 40 and sends a current sensed signal to the controller 420 forcontrolling the operation of the output-controlling unit 40.

Reference is made to FIG. 2, which is a circuit diagram of a powerconversion system according to the first embodiment of the presentdisclosure. The switching module 10 is electrically connected to theinput voltage Vi and includes a first power switch QA, a second powerswitch QB, a third power switch QC, and a fourth power switch QD. Thefirst to fourth switches QA^(˜)QD are, for example,metal-oxide-semiconductor field-effect transistors (MOSFETs). The drainsof the first power switch QA and the third power switch QC are connectedto the input voltage Vi, the source of the first power switch QA isconnected to the drain of the second power switch QB, and the source ofthe third power switch QC is connected to the drain of the fourth powerswitch QD and the primary winding 310. The sources of the second powerswitch QB and the fourth power switch QD are connected to the inputvoltage Vi.

The switching module 10 may further includes a plurality of diodes D anda plurality of capacitors C electrically connected to the first tofourth power switches QA^(˜)QD. Specifically, the diodes D are, forexample, the body diodes of the first to fourth power switches QA^(˜)QD,and the capacitors C are, for example, parasitic capacitances of thefirst to fourth power switches QA^(˜)QD; the cathode of each diode D isconnected to the drain of one of the first to fourth power switchesQA^(˜)QD, the anode thereof is connected to the source of one of thefirst to fourth power switches QA^(˜)QD, and each of the capacitors C iselectrically connected to one of the diodes D in parallel.

The resonant module 20 includes a resonant inductor Lr, a direct-current(DC) isolating capacitor Cb, and a magnetizing inductor. In FIG. 2, theresonant inductor Lr and the isolating transformer 30 are shownintegrally; nevertheless, they are able to be separated in the practicalmanufacturing process. The DC isolating capacitor Cb, the resonantinductor Lr, and the primary winding 310 are electrically connected inseries. specifically, one terminal of the DC isolating capacitor Cb isconnected to the sources of the first power switch QA and second powerswitch QB, and the other terminal of the DC isolating capacitor Cb isconnected to one terminal of the resonant inductor Lr, and the otherterminal of the resonant indictor Lr is connected to the primary winding310.

The first to fourth power switches QA^(˜)QD of the resonant module 20are controlled using a zero-voltage-switching (ZVS) scheme to reduceswitching loss.

The output-controlling device 40 includes a first synchronous rectifyingunit 410 a, a second synchronous rectifying unit 410 b, a thirdsynchronous rectifying unit 410 s, a fourth synchronous rectifying unit410 d, a first output switch SW1, a second output switch SW2, a thirdoutput switch SW3, and a fourth power switch SW4. The first synchronousrectifying unit 410 a is connected to the secondary winding 320 a andthe first output switch SW1, the second synchronous rectifying unit 410b is electrically connected to the secondary winding 320 b and thesecond output switch SW2, the third synchronous rectifying unit 410 c iselectrically connected to the secondary winding 320 c and the thirdoutput switch SW3, and the fourth synchronous rectifying unit 410 d iselectrically connected to the secondary winding 320 d and the fourthoutput switch SW4.

The first synchronous rectifying unit 410 a includes rectifying switchesQ1 and Q2, the second synchronous rectifying unit 410 b includesrectifying switches Q3 and Q4, the third synchronous rectifying unit 410c includes rectifying switches Q5 and Q6, and the fourth synchronousrectifying unit 410 d includes rectifying switches Q7 and Q8. Therectifying switches Q1 to Q8 are, for example, MOSFETs.

The source of the rectifying switch Q1 is connected to the source of therectifying switch Q2, and the drains of the rectifying switches Q1 andQ2 are respectively connected to the secondary winding 320 a (the drainof the rectifying switch Q1 is connected to one terminal of thesecondary winding 320 a, and the drain of the rectifying switch Q2 isconnected to the other terminal of the secondary winding 320 a). Thesource of the rectifying switch Q3 is connected to the source of therectifying switch Q4, and the drains of the rectifying switches Q3 andQ4 are respectively connected to the secondary winding 320 b. The sourceof the rectifying switch Q5 is connected to the source of the rectifyingswitch Q6, and the drains of the rectifying switches Q5 and Q6 arerespectively connected to the secondary winding 320 c. The source of therectifying switch Q7 is connected to the source of the rectifying switchQ8, and the drains of the rectifying switches Q7 and Q8 are respectivelyconnected to the secondary winding 320 d. The gates SR1 ^(˜)SR8 of therectifying switches Q1 ^(˜)Q8 are electrically connected to thecontroller 420, and the rectifying switches Q1 ^(˜)Q8 are controlled bythe controller 420 using a synchronous rectifying scheme.

The power conversion system further includes filters L1 ^(˜)L8, whichare, for example, chokes. The filters L1 and L2 are arranged between thesecondary winging 320 a and the first output switch SW1, the filter L3and L4 are arranged between the secondary winding 320 b and the secondoutput switch SW2, the filter L5 and L6 are arranged between thesecondary winding 320 c and the third output switch SW3, and the filterL7 and L8 are arranged between the secondary winding 320 d and thefourth output switch SW4. Specifically, each secondary winding 320 a^(˜) 320 d has two terminals, one terminal of the secondary winding 320a is connected to the filter L1, and the other terminal thereof isconnected to the filter L2; one terminal of the secondary winding 320 bis connected to the filter L3, and the other terminal thereof isconnected to the filter L4; one terminal of the secondary winding 320 cis connected to the filter L5, and the other terminal thereof isconnected to the filter L6; one terminal of the secondary winding 320 dis connected to the filter L7, and the other terminal thereof isconnected to the filter L8.

The power conversion system still further includes a plurality of outputcapacitors Co. One terminal of the output capacitor is connected tosynchronous rectifying unit 410 a ^(˜) 410 d, and the other terminalthereof is connected to one of the first to fourth output switch SW1^(˜)SW4.

It should be noted that the power conversion system is configured toprovide different powers to meet the power required for the electronicdevice. Therefore, the controller 420 may measure the power required forthe electronic device by the current sensed signal representing thecurrent flowing through the sensing resistor Rs sent from the currentsense unit 50 and place at least one of the synchronous rectifying units410 a ^(˜) 410 d or at least one of the first to fourth output switchSW1 ^(˜)SW4 in a conducting state to conduct the power required for theelectronic device to the electronic device. It should be noted that whenthe synchronous rectifying 410 a ^(˜) 410 d are in the conducting state,the powers coupled to the secondary winding 320 a ^(˜) 320 d areconducted to the synchronous rectifying units 410 a ^(˜) 410 d, and asynchronous rectifying procedure is performed. On the contrary, when thesynchronous rectifying units 410 a ^(˜) 410 d are not in the conductingstate (or called the synchronous rectifying units 410 a ^(˜) 410 d arein a non-conducting state), the power transmitted to the primary winding310 cannot conducted to the secondary windings 320 a ^(˜) 320 d, and thesynchronous rectifying procedure is not performed. Besides, when thefirst to fourth output switches SW1 ^(˜)SW4 are in the conducting state,the first to fourth output switches SW1 ^(˜)SW4 turn on (close), thepowers with synchronous rectification are conducted to the outputcapacitors Co and the output Vo. One the contrary, when the first tofourth output switches SW1 ^(˜)SW4 are in the non-conducting state, thefirst to fourth output switches SW1 ^(˜)SW4 turn off (open), the powerswith synchronous rectification cannot be conducted to the outputcapacitors Co and the output Vo.

The isolating transformer 30 and the resonant inductor Lr (if exist)provide a leakage inductance. In order to achieve higher efficienciesand lower electromagnetic interferences (EMI), a zero voltage switching(ZVS) mode is operated. With ZVS mode, during operation, the first tofourth power switches QA^(˜)QD in a switching stage of the powerconversion system are activated at zero crossings of their main terminalvoltage to minimize turn on losses. An amount of time is required by thefirst to fourth power switches QA^(˜)QD to turn off (open) and on(close). The overlap between these transitions can be referred to asdead-time (as time points between t2 and t3 and the time points betweent4 and t5 shown in the FIG. 4a ). A minimum amount of dead-time isneeded to avoid having the first power switch QA and second power switchQB (or the third power switch QC and the fourth power switch QD) closed(turned on) at the same time. If the first power switch QA and thesecond power switch QB (or the third power switch QC and the fourthpower switch QD) are closed at the same time, potentially destructiveshoot-through current that travels directly from input voltage Vi toelectronic device may result. The period of the dead-time is risesgradually as leakage inductance is increased. The gates of the first tofourth power switches QA^(˜)QD are electrically connected to acontrolling circuit (not shown), and the first to fourth power switchesQA^(˜)QD are turned off and on according to signals sent from thecontrolling circuit.

Reference is made to FIG. 2 and FIG. 4a , wherein FIG. 4a is a timingchart indicating operations of the power conversion system during lightload condition. In order to clarify detailed operation of the powerconversion system of the present disclosure, the following example isgiven. It should be noted that the values given in the example are onlyfor clarity. The values can be changed to meet system requirements.During the heavy load condition, the power (including voltage andcurrent) provided by the power conversion system is the largest. As theload lightens, the power is reduced. During the light load condition,the power provided by the power conversion system reduces to, forexample, 20%; during the normal load condition, the power provided bythe power conversion system reduces to, for example, 50%.

Seven time points t1-t7 are shown in the FIG. 4a . With the second powerswitch QB and the third power switch QC are closed (placed in conductingstates) (wherein the first power switch QA and the fourth power switchQD are opened) to provide a conduction path between time points t1 andt2, a primary current Ip from the input voltage Vi flows through thethird power switch QC, the primary winding 310, the resonant module 20,the second power switch QB to the ground. During this time, energy isstored in the resonant inductor Lr, and the primary current (Ip) israised.

The second power switch QB is then opened at time point t2 (the thirdpower switch QC is continuously closed), and then a short time durationlater, the first power switch QA is closed (at time point t3). Duringthis short duration, the current supported by the energy stored in theisolating transformer's leakage inductance, and optionally in resonantinductor Lr, now flows out of the capacitances C associated with thefirst power switch QA and the second power switch QB and into the thirdpower switch QC (which is still closed). Specifically, when the secondpower switch QB is opened, the primary current Ip freewheels through thediode D associate with the first power switch QA, and the capacitor Cassociated with the second power switch QB is charged, and the capacitorC associated with the first power switch QA is discharged until thepotential of the capacitor C associates with the second power switch QBis equal to that of the input voltage Vi.

When a voltage across drain-source of the first power switch QA is lowerthan a voltage across the forward bias of the diode D associated withthe first power switch QA, the diode D associate with the first powerswitch QA turns on (placed in conducting states). As such, the firstpower switch QA is closed under zero-voltage condition (i.e., zerovoltage switching). Due to that the voltage across drain-source of thefirst power switch QA is lower than the voltage across the diode Dassociate with the first power switch QA, the conduction loss is low. Atthis time, the primary voltage Vp of the power conversion system iszero.

Between time points t4 and t5, the third power switch QC is closed andthe current freewheels through the diode D associated with the fourthpower switch QD. During this short duration, the current supported bythe energy stored in the isolating transformer's leakage inductance, andoptionally in resonant inductor Lr, now flows out of the capacitances Cassociated with the third power switch QC and the fourth power switch QDand into the first power switch QA (which is still closed).Specifically, when the third power switch QC is opened, the primarycurrent Ip freewheels through the diode D associate with the fourthpower switch QD, and the capacitor C associated with the third powerswitch QC is charged, and the capacitor C associated with the fourthpower switch QD is discharged until the potential of the capacitor Cassociates with the third power switch QC is equal to that of the inputvoltage Vi and a voltage across drain-source of the second power switchQD is dropped to zero (as curve VQ4 shown).

When a voltage across drain-source of the fourth power switch QD islower than a voltage across the forward bias of the diode D associatedwith the fourth power switch QD, the diode D associate with the fourthpower switch QD turns on (placed in conducting states). As such, thefourth power switch QD is closed under zero-voltage condition.

Due to the voltage across the resonant inductor Lr is equal to the inputvoltage Vi, the primary current Ip is linearly decreased between timepoints t5 and t6. In FIG. 4a , a duty cycle loss appears between timepoints t5 and t6 since a primary voltage Vp does not drop to negativevalue at time point t5, which the fourth power switch QD is closed(wherein the fourth power switch QD is closed at time point t6). Themore the leakage inductance is, the more duty cycle loss is, and theduty cycle loss is given by

Lr*(Ip/Vp)

wherein

Lr is the inductance of the resonant inductor;

Ip is the primary current of the power conversion system; and

Vp is the primary voltage of the power conversion system.

FIG. 5a is a timing chart indicating operations of the power conversionsystem during normal load condition. FIG. 6a is a timing chartindicating operations of the power conversion system during heavy loadcondition. The function and relative description of the power conversionsystem during normal load condition and during heavy load condition arethe same as that of during light load condition mentioned above and arenot repeated here for brevity. It should be noted that the currentprovided by the power conversion system is increased while the power(current) required for the electronic device is increased, and the dutycycle loss of the power conversion system is increased while the currentprovided by the power conversion system is increased. As such, a hold-uptime depends upon the duty cycle loss is then decreased, that result inlower efficiency. Specifically, if the input voltage Vi falls below theminimum permissible voltage and adversely affects the power conversionsystem operation, the electronic devices that rely on the powerconversion system for power could experience critical failures such asthe loss of data. The length of time that the power conversion systemcan continue to operate in the absence of line voltage is referred to asthe hold-up time.

If power conversion system is to provide a better efficiency, then alower duty cycle loss will be needed. As a result, a distinctiveoperation of the output-controlling device 40 is required to meet theduty cycle loss required to keep the efficiency of the power conversionsystem within acceptable limits.

In general, the power provided by the power conversion system dependsupon the power required for the electronic device. More particularly,the power required for the electronic device during heavy load conditionis higher than that of during the light load condition. Therefore, thepower (such as current) provided by the power conversion system whilethe electronic device operated under heavy load condition will be higherthan that of operated under light load condition.

The output-controlling device 40 of the present disclosure is controlledto make the current provided by the power conversion system to meet thepower required for the electronic device.

The power conversion system may provide the power to meet the requiredfor the electronic device depends upon the operation of the first tofourth synchronous rectifying units 410 a ^(˜) 410 d of theoutput-controlling module 400 a ^(˜) 400 d. Reference is made back toFIG. 2 and FIG. 3. In first operation state, when a first current I1 isrequired for the electronic device, the controller 420 sends signals togates SR1 ^(˜)SR8 of the rectifying switches Q1 ^(˜)Q8 according to thecurrent sensed signal sent from the current sense unit 50 for indicatingthat the first current I1 is required by the electronic device, andplaces one of the first to fourth rectifying unit 410 a ^(˜) 410 d inthe conducting state for performing synchronous rectifying procedure,thus the first current I1 is provided by the power conversion system.Specifically, the controller 420 may send pulsating signals to drive therectifying switches Q1 and Q2 to interleaved turn off and on (as timepoints between 0^(˜)t1 shown in FIG. 3), thus a power coupled to thesecondary winding 320 a is synchronous rectified by the firstsynchronous rectifying unit 410 a and the rectified power is thenconducted to the output terminal (connected to the electronic device) bypassing through the filters L1 and L2, the first output switch SW1, andthe output capacitor Co connected to the first output switch SW1.

In second operation state, when a second current I2 is required for theelectronic device, the controller 420 receives the current signal sentfrom the current sense unit for indicating that the second current I2 isrequired by the electronic device, and sends signals to the gates SR1^(˜)SR8 for placing two of the first to fourth synchronous rectifyingunits 410 a ^(˜) 410 d in the conducting state for performingsynchronous rectifying procedure, thus the second current I2 is thenprovided by the power conversion system, the second current I2 is largerthan the first current I1. Specifically, the controller 420 may sendpulsating signals to drive the rectifying switches Q1 ^(˜)Q4 tointerleaved turn off and on (as time points between t1 and t2 shown inFIG. 3), thus powers coupled to the secondary winding 320 a and 320 bare synchronous rectified by the first and second synchronous rectifyingunits 410 a and the 410 b, respectively, and the rectified powers arethen conducted to the output terminal (connected to the electronicdevice) by passing through the filters L1 ^(˜)L4, the first power switchSW1, second output switch SW2, and the output capacitors Co connected tothe first power switch SW1 and the second output switch SW2.

In third operation state, when a third current I3 is required for theelectronic device, the controller 420 receives the current sensed signalsent from the current sense unit 50 for indicting that the third currentis required for the electronic device, and sends signals the gates SR1^(˜)SR8 for placing three of the first to fourth synchronous rectifyingunit 410 a ^(˜) 410 d in the conducting state for performing synchronousrectifying procedure, thus the third current I3 is then provided by thepower conversion system, the third current I3 is larger than the secondcurrent I2. Specifically, the controller 420 may send pulsating signalsto drive the rectifying switches Q1 ^(˜)Q6 to interleaved turn off andon (as time points between t2 and t3 shown in FIG. 3), thus powerscoupled to the secondary windings 320 a ^(˜) 320 c are synchronousrectified by the first to third synchronous rectifying units 410 a ^(˜)410 c, respectively, and the rectified powers are then conducted to theoutput terminal (connected to the electronic device) by passing throughthe filters L1 ^(˜)L6, the first to third output switch SW1 ^(˜)SW3, andthe output capacitors Co connected to the first to third output switchSW1 ^(˜)SW3.

In fourth operation state, when a fourth current I4 is required for theelectronic device, the controller 420 receives the current sensed signalsent from the current sense unit for indicating that the third currentis required for the electronic device, and sends signals to the gatesSR1 ^(˜)SR8 for placing all of the first to fourth synchronousrectifying unit 410 a ^(˜) 410 d in the conducting state for performsynchronous rectifying procedure, thus a fourth current I4 is thenprovided by the power conversion system, the fourth current I4 is largerthan the third current I3. Specifically, the controller 420 may sentpulsating signals to drive the rectifying switches Q1 ^(˜)Q8 tointerleaved turn on and off continuously (after time point t3 shown inFIG. 3), thus powers coupled to the secondary winding 320 a ^(˜) 320 dare synchronous rectified by the first to fourth synchronous rectifyingunits, respectively, and the rectified power are then conducted to theoutput terminal (connected to the electronic device) by passing throughthe filters L1 ^(˜)L8, the first to fourth output switch SW1 ^(˜)SW4 andthe output capacitors Co.

As such, an effect of energy conservation is provided and the power losswhile the electronic device operated under light load condition isreduced since the first to the fourth rectifying unit 410 a ^(˜) 410 dare separately placed in the conducting state and driven to synchronousrectify the powers coupled to the secondary windings 320 a ^(˜) 320 d.

The controller 420 may selectively place the first to fourth switchesSW1 ^(˜)SW4 in the conducting state for conducting power required forthe electronic device to the output terminal. It should be noted whenthe controller 420 places at least one of the first to fourthsynchronous rectifying units 410 a ^(˜) 410 d in the conducting statefor conducting power require for the electronic device to the outputterminal, the first to fourth switches SW1 ^(˜)SW4 are always closed tomake the rectified power(s) flowing therethrough; when the controller420 places at least one of the first to fourth switch SW1 ^(˜)SW4 in theconducting state for conducting power required for the electronic deviceto the output terminal, the controller 420 sends the pulsating signalsto the rectifying switches Q1 ^(˜)Q8 to makes the first to fourthsynchronous rectifying units 410 a ^(˜) 410 d perform synchronousrectifying procedure all the time.

Reference is made back to FIG. 2 and FIG. 3. The controller 420 mayplace the first switch SW1 in the conducting state for conduct a powercoupled to the secondary winding 320 a and rectified by the firstsynchronous rectifying unit 410 a to the output terminal (connected tothe electronic device) in first operation state, therefore the firstcurrent I1 is provided to the electronic device (as the time pointsbetween 0 and t1 shown in the FIG. 3).

In second operation state, the controller 420 may place the first switchSW1 and the second switch SW2 in the conducting state for conductingpowers coupled to the secondary windings 320 a and 320 b and rectifiedby the first synchronous rectifying unit 410 a and the secondsynchronous rectifying unit 410 b to the output terminal (connected tothe electronic device), therefore the second current I2 is provided tothe electronic device (as the time points between t1 and t2 shown in theFIG. 3), wherein the second current I2 is larger than the first currentI1.

In third operation state, the controller 420 may place the first tothird switches SW1 ^(˜)SW3 in the conducting state for conducting powerscoupled to the secondary windings 320 a ^(˜) 320 c and rectified by thefirst to third synchronous rectifying units 410 a ^(˜) 410 c to theoutput terminal (connected to the electronic device), therefore thethird current I3 is provided to the electronic device (as the timepoints between t2 and t3 shown in the FIG. 3), wherein the third currentI3 is larger than the second current I2.

The controller 420 places the first to fourth switches SW1 ^(˜)SW4 inthe conducting state for conducting powers coupled to the secondarywindings 320 a ^(˜) 320 d and rectified by the first to fourthsynchronous rectifying units 410 a ^(˜) 410 d to the output terminal(connected to the electronic device), therefore the fourth current I4 isprovided to the electronic device (as the time point t3 shown in theFIG. 3), wherein the fourth current I4 is larger than the third currentI3.

The arrangement of the primary winding 310 and the second windings 320 a^(˜) 320 d of the present disclosure is further controlled to lower thepower loss of the power conversion system.

Reference is made to FIG. 7, which is a cross-sectional view of theisolating transformer according to the first embodiment of the presentdisclosure. The isolating transformer 30 further includes a bobbin 330and a magnetic core 340, and the magnetic core 340 is assembled with thebobbin 330. The primary winding 310 and the secondary winding 320 a ^(˜)320 d are placed on the bobbin 330. In FIG. 7, the isolating transformer30 includes one primary winding 310 and four secondary windings 320 a^(˜) 320 d, the secondary windings 320 a ^(˜) 320 d are arranged at thebobbin 330 with equidistance intervals (such as inserted into slotspreset on the bobbin 330 with equidistance intervals), the primarywinding 310 is wound on the bobbin 330 (where the secondary windings 320a ^(˜) 320 d does not placed and across each of the secondary windings320 a ^(˜) 320 d). As a result, the primary winding 310 and thesecondary windings 320 a ^(˜) 320 d are arranged in a staggered mannerin a side view direction, i.e., the primary winding 310 is placed atsame side of each secondary winding 320 a ^(˜) 320 d (wherein in FIG. 7,the primary winding 310 is wound on the bobbin 310 and placed at theleft side of the secondary winding 320 a ^(˜) 320 d).

Reference is made back to FIG. 2 and FIG. 7, the power conversion systemmay provide power required for the electronic device by controlling theoperation states of the output-controlling modules 400 a ^(˜) 400 d.

In one of the operation states, the controller 420 may send pulsatingsignals to drive the rectifying switches Q1 ^(˜)Q8 to performsynchronous rectifying procedure. As a result, the power coupled to thesecond windings 320 a ^(˜) 32 d is synchronously rectified by the firstto fourth synchronous rectifying units 410 a ^(˜) 410 d, and therectified powers are then conducted to the output terminal (connected tothe electronic device) by passing through the conducted first to fourthswitches SW1 ^(˜)SW4. Selectively, the controller 420 may drive thefirst to fourth switches SW1 ^(˜)SW4 to close and then conduct the powercoupled to the second windings 320 a ^(˜) 320 d and rectified by thefirst to fourth synchronous rectifying units 410 a ^(˜) 410 d to theoutput terminal (connected to the electronic device). As a result, aleakage inductance based on the magnetic coupling between the primarywinding 310, the secondary windings 320 a ^(˜) 320 d, and optionally inresonant inductor Lr is generated.

Reference is made to FIG. 8, the lowest leakage inductance appears atthe points that each of the second windings 320 a ^(˜) 320 d is close tothe primary winding 310, and the leakage inductance is increased whenthe coupling distance between each of the secondary windings 320 a ^(˜)320 d and the primary winding 310 is increased. The leakage inductancevaries in a fixed range since the primary winding 310 and the secondarywindings 320 a ^(˜) 320 d are arranged in the staggered manner.

In another operation state, the controller 420 may send pulsatingsignals to the rectifying switches Q1 ^(˜)Q2 to drive the firstsynchronous rectifying unit 410 a perform synchronous rectifyingprocedure (wherein the rectifying switches Q3 ^(˜)Q8 are always opened).As a result, only the power coupled to the second windings 320 a issynchronously rectified by the first synchronous rectifying units 410 a,and the rectified power is then conducted to the output terminal(connected to the electronic device) by passing through the conductedfirst to fourth switches SW1 ^(˜)SW4. Selectively, the controller 420may drive the first switch SW1 to close and conduct the power coupled tothe second windings 320 a and rectified by the first synchronousrectifying units 410 a to the output terminal (connected to theelectronic device). Another leakage inductance based on the magneticcoupling between the primary winding 310, the secondary windings 320 a,and optionally in resonant inductor Lr is generated.

Reference is made to FIG. 9, the lowest leakage inductance appears atthe point between the second winding 320 a and the primary winding 310,and the leakage inductance is increased when the coupling distancebetween the secondary winding 320 a and the primary winding 310 isincreased.

In the other state, the controller 420 may send pulsating signals to therectifying switches Q3 ^(˜)Q6 to drive the second synchronous rectifyingunit 410 b and the third synchronous rectifying unit 410 c to performsynchronous rectifying procedure (wherein the rectifying switches Q1,Q2, Q7, and Q8 are always opened). As a result, only the powers coupledto the second windings 320 b and 320 c are synchronously rectified bythe second synchronous rectifying units 410 b and the third synchronousrectifying units 410 c, and the rectified powers are then conducted tothe output terminal (connected to the electronic device) by passingthrough the conducted first to fourth switches SW1 ^(˜)SW4. Selectively,the controller 420 may drive the second switch SW2 and the third switchSW3 to close and conduct the powers coupled to the second windings 320 band 320 c and rectified by the second synchronous rectifying unit 410 band the third synchronous rectifying units 410 c to the output terminal(electrically connected to the electronic device). Still another leakageinductance based on the magnetic coupling between the primary winding310, the secondary windings 320 b and 320 c, and optionally in resonantinductor Lr is generated.

Reference is made to FIG. 10, the lowest leakage inductance appears atthe point between the second windings 320 b, 320 c and the primarywinding 310, and the leakage inductance is increased when the couplingdistance between the secondary winding 320 b, 320 c and the primarywinding 310 is increased.

In sum, the amount of the first to fourth synchronous rectifying units410 a ^(˜) 410 d performing synchronous rectifying procedure and thecoupling distance between the secondary winding 320 a ^(˜) 320 dperforming synchronous rectifying and the primary windings 310 affectsthe leakage inductance of the power converting system. As such, byeffectively controlling the amount of the first to fourth synchronousrectifying units 410 a ^(˜) 410 d performing synchronous rectifyingprocedure and the coupling distance mentioned above, the powerconversion system can accurately provide power required for theelectronic device to the electronic device.

It should be noted that the power conversion system provides power tothe electronic device only when the synchronous rectifying unit (410 a^(˜) 410 d) connected to the particular secondary winding (320 a ^(˜)320 d) performs synchronous rectifying procedure and the output switch(SW1 ^(˜)SW4) connected to the synchronous rectifying (410 a ^(˜) 410 d)is close. For example, reference is made to FIG. 2, when the firstsynchronous rectifying unit 410 a performs synchronous rectifyingprocedure and the first switch SW1 is close, the power conducted to theprimary winding 310 is coupled to the secondary winding 320 a connectedto the first synchronous rectifying unit 410 a, and then the rectifiedpower is conducted to the electronic device by passing through thefilters L1 and L2. In the meanwhile, a leakage inductance based on themagnetic coupling between the primary winding 310 and the secondarywindings 320 a ^(˜) 320 d is generated.

The detail data of the leakage inductance in different operation statesare shown in Table 1.

TABLE 1 1st 2nd 3rd 4th Leakage synchronous synchronous synchronoussynchronous induc- rectifying rectifying rectifying rectifying tanceunit unit unit unit (μH) 1st non- non- non- conducting 25.19 stateconducting conducting conducting state state state state 2nd conductingnon- non- non- 24.4 state state conducting conducting conducting statestate state 3rd conducting non- non- conducting 14.59 state stateconducting conducting state state state 4th non- non- conducting non-12.3 state conducting conducting state conducting state state state 5thnon- conducting non- non- 12.2 state conducting state conductingconducting state state state 6th non- non- conducting conducting 11.93state conducting conducting state state state state 7th conductingconducting non- non- 10.13 state state state conducting conducting statestate 8th conducting non- conducting conducting 9.95 state stateconducting state state state 9th conducting non- conducting non- 9.9state state conducting state conducting state state 10th non- conductingnon- conducting 9.89 state conducting state conducting state state state11th conducting conducting non- conducting 8.29 state state stateconducting state state 12th conducting conducting conducting non- 8.2state state state state conducting state 13th non- conducting conductingconducting 8.12 state conducting state state state state 14th conductingconducting conducting conducting 8.02 state state state state state 15thnon- conducting conducting non- 8 state conducting state stateconducting state state

In Table 1, “conducting state” means that the synchronous rectifyingunit (410 a ^(˜) 410 d) is places in the conducting state and performssynchronous rectifying procedure, thus the power conducted to theprimary winding 310 may be coupled to particular secondary winding (320a ^(˜) 320 d) connected to the synchronous rectifying unit (410 a ^(˜)410 d) placed in the conducting state, and a rectified power is thenconducted to the electronic device; nevertheless, “non-conducting state”means that the synchronous rectifying unit 410 a ^(˜) 410 d is places inthe non-conducting state and does not perform synchronous rectifyingprocedure, and the power conducted to the primary winding 310 does notcoupled to the secondary winding 320 a ^(˜) 320 d connected to thesynchronous rectifying unit 410 a ^(˜) 410 d placed in thenon-conducting state.

Reference is made to FIG. 4b , which is another timing chart indicatingoperations of the power conversion system during light load condition.It should be noted that the timing chart shown in the FIG. 4b indicatesthe power conversion system which the amount of the first to fourthsynchronous rectifying units 410 a ^(˜) 410 d performing synchronousrectifying procedure and the coupling distance between the secondarywinding 320 a ^(˜) 320 d connected to the first to fourth synchronousrectifying units 410 a ^(˜) 410 d performing synchronous rectifyingprocedure and the primary windings 310 are controlled as mentionedabove. In FIG. 4b , a duty cycle loss appears between time points t5 andt6′ since a primary voltage Vp does not drop to negative value at timepoint t5, which the fourth power switch QD is closed. Comparing to theFIG. 4a (the duty cycle loss appears between time points t5 and t6), theduty cycle loss shown in the FIG. 4b is reduced (the period between timepoints t6′ and t6 shown in the FIG. 4b indicates the duty cycle losswhich is eliminated from FIG. 4a ).

FIG. 5b is another timing chart indicating operations of the powerconversion system during normal load condition. FIG. 6b is anothertiming chart indicating operations of the power conversion system duringheavy load condition. In FIGS. 5b and 6b , the period between timepoints t5 and t6 indicates duty time loss of the power conversion systemwhich the amount of the synchronous rectifying units performingsynchronous rectifying procedure and the coupling distance between thesecondary winding 320 a ^(˜) 320 d and the primary windings 310 are notcontrolled (for example, the first to fourth synchronous rectifyingunits 410 a ^(˜) 410 d perform synchronous rectifying procedure as thesame time). On the contrary, the period between time points t5 and t6′indicates duty time loss of the power conversion system which the amountof the synchronous rectifying units performing synchronous rectifyingprocedure and the coupling distance between the secondary winding 320 a^(˜) 320 d and the primary windings 310 are well controlled (wherein theperiod between time points t6′ and t6 shown in the FIG. 5b and FIG. 6bindicates the duty cycle loss which is eliminated from FIGS. 5a and 6a).

In order to prevent generated heat that arises at the time of drivingfrom being stored, the first to fourth synchronous rectifying units 410a ^(˜) 410 d may perform synchronous rectifying procedure in sequence.For example, the controller 420 may progressively increase the amount ofthe synchronous rectifying units (410 a ^(˜) 410 d) performingsynchronous rectifying procedure when the power required for theelectronic device is gradually increased. In addition, the controller420 may drives the synchronous rectifying units (410 a ^(˜) 410 d) in aconvergence manner when only one of the synchronous rectifying units(410 a ^(˜) 410 d) performs synchronous rectifying procedure. Moreparticularly, the convergence manner may first make the synchronousrectifying unit (410 a ^(˜) 410 d) far from a central axis of theisolating transformer 30 shown in the FIG. 7 perform synchronousrectifying procedure, and next makes the synchronous rectifying unitsclose to the central axis of the transformer shown in the FIG. 7 toprevent generated heat that arises at the time of driving from beingstored, i.e., the controller 420 may makes the first synchronousrectifying units 410 a, the fourth synchronous rectifying units 410 d,the second synchronous rectifying units 410 b, and the third synchronousrectifying units 410 c shown in the FIG. 7 perform synchronousrectifying procedure in sequence. It should be noted that if thedistances between two synchronous rectifying units and the central axisare the same, the two synchronous rectifying units interleaved performsynchronous rectifying procedure.

Reference is made back to Table 1, in 1st and 2nd states, they are onlyone of the synchronous rectifying units is placed in the conductingstate and performs synchronous rectifying procedure. As can be shown inFIG. 7, the distance between the synchronous rectifying unit performingsynchronous rectifying procedure in 1st state and the central axis ofthe isolating transformer 30 is equal to that of in 2nd state, and theleakage inductance in 1st state is close to that of in 2nd state.Therefore, the controller 420 may interleaved drive the firstsynchronous rectifying unit 410 a and the fourth synchronous rectifyingunit 410 d to conduct the power coupled to the secondary winding 320 aand 320 d to the electronic device while the electronic device isoperated under the same condition (such as light load condition) toprevent generated heat that arises at the time of driving from beingstored in particular synchronous rectifying unit (410 a ^(˜) 410 d),which is placed in the conducting state and performs synchronousrectifying procedure all the time.

It should be noted that the synchronous rectifying units (410 a ^(˜) 410d) may be interleaved placed in the conducting state (i.e. the first tofourth synchronous rectifying units 410 a ^(˜) 410 d may be driven tointerleaved perform synchronous rectifying procedure) according to thedistance between the central axis and the synchronous rectifying units(410 a ^(˜) 410 d), for example, the synchronous rectifying units (410 a^(˜) 410 d) with same distance from the central axis may be interleaveddriven to perform synchronous rectifying procedure. However, that thesynchronous rectifying units (410 a ^(˜) 410 d) may be driven tointerleaved perform synchronous rectifying procedure according toinductance in different operation states of the synchronous rectifyingunits (410 a ^(˜) 410 d). For example, the operation states with similarleakage inductance (such as the difference in leakage inductance betweenthe operation states is less than 5 μH) may be interleaved driven toperform synchronous rectifying procedure.

In sum, the power conversion system of the present disclosure performs apower conversion procedure for powering the electronic device includesstep as following first, the power conversion system including a primarywinding 310, a plurality of secondary windings 320 a ^(˜) 320 d, and aplurality of synchronous rectifying units 410 a ^(˜) 410 d is provided.There are a plurality of coupling distances between the primary winding310 and the secondary windings 320 a ^(˜) 320 d.

Next, the operation condition (such as light load condition, normal loadcondition, or heavy load condition) of the electronic device is measuredby measuring a current required by the electronic device. Specifically,the current required for the electronic device during light loadcondition may be smaller than that of during normal load condition, andthe current required for the electronic device during heavy loadcondition may be larger than that of during normal load condition.Thereafter, the synchronous rectifying units (410 a ^(˜) 410 d) areselectively placed in a conducting state for varying a leakageinductance of the power conversion system, thus a output current of thepower conversion system is modulated to meet the current requirement ofthe electronic device. The output current is only provided by thesynchronous rectifying units 410 a ^(˜) 410 d which is placed in theconducting state, and the power conversion system has a lowest leakageinductance when all of the output-controlling modules 400 a ^(˜) 400 dare placed in the conducting state, therefore a largest output currentis provided.

The power conversion system may vary the leakage inductance byselectively place one of the synchronous rectifying units 410 a ^(˜) 410d in the conducting state at a time; however, the power conversionsystem may further selectively place two or more synchronous rectifyingunits 410 a ^(˜) 410 d at a time. Besides, the leakage inductance of thepower conversion system is varied when an amount of the synchronousrectifying units 410 a ^(˜) 410 d placed in the conducting statechanges.

Reference is made to FIG. 11, which is a circuit diagram of a powerconversion system according to a second embodiment of the presentdisclosure. In FIG. 11, the power conversion system includes a switchingmodule 10, a resonant module 20, a transformer 30, and anoutput-controlling device 40. The transformer 30 includes a primarywinding 310 and a plurality of secondary windings 320 a ^(˜) 320 dcoupled with the primary winding 310.

The function and relative description of switching module 10 and theresonant module 20 of the power conversion system shown in the FIG. 11are the same as that of first embodiment (shown in the FIG. 2) mentionedabove and are not repeated here for brevity, and the switching module 10and the resonant module 20 of the power conversion system shown in theFIG. 11 can achieve the functions as power conversion system of thefirst embodiment does. It should be noted that the transformer 30 andthe output-controlling device 40 shown in the FIG. 11 is different fromthat of the first embodiment.

In FIG. 11, the transformer 30 is a center-tapped transformer, which hasan advantage of compact. However, the isolating transformer shown inFIG. 2 has an advantage of double-current. The output-controlling device40 is electrically connected to the secondary winding 320 a ^(˜) 320 dof the transformer and includes first to fourth synchronous rectifyingunits 410 a ^(˜) 410 d, controller 420, and first to fourth outputswitch SW1 ^(˜)SW4. The first synchronous rectifying unit 410 a isconnected to the secondary winding 320 a, the second synchronousrectifying unit 410 b is connected to the secondary winding 320 b, thethird synchronous rectifying unit 410 c is connected to the secondarywinding 320 c, and the fourth synchronous rectifying unit 410 d isconnected to the secondary winding 320 d.

The first synchronous rectifying unit 410 a includes rectifying switchesQ1 and Q2, the second synchronous rectifying unit 410 b includesrectifying switches Q3 and Q4, the third synchronous rectifying unit 410c includes rectifying switches Q5 and Q6, and the second synchronousrectifying unit 410 d includes rectifying switches Q7 and Q8.Specifically, the sources of the rectifying switch Q1 and Q2 areconnected to ground, the drains thereof is connected to two taps of thesecond winding 320 a, and the filter L1 is connected to the center-tapof the second winding 320 a; the sources of the rectifying switch Q3 andQ4 are connected to ground, the drains thereof is connected to two tapsof the second winding 320 b, and the filter L2 is connected to thecenter-tap of the second winding 320 b; the sources of the rectifyingswitch Q5 and Q6 are connected to ground, the drains thereof isconnected to two taps of the second winding 320 c, and the filter L3 isconnected to the center-tap of the second winding 320 c; the sources ofthe rectifying switch Q7 and Q8 are connected to ground, the drainsthereof is connected to two taps of the second winding 320 d, and thefilter L4 is connected to the center-tap of the second winding 320 d.The gates SR1 ^(˜)SR8 of the rectifying switch Q1 ^(˜)Q8 and the firstto fourth output switch SW1 ^(˜)SW4 are connected to the controller 420.The controller 420 sends signals the rectifying switch Q1 ^(˜)Q8 todrive one of the first the fourth synchronous rectifying units 410 a^(˜) 410 d to perform synchronous rectifying procedure. The controller420 further sent signals to the first to fourth output switch SW1^(˜)SW4 to makes one of the first to fourth output switch SW1 ^(˜)SW4 toturn off or on, wherein when the first to fourth output switch SW1^(˜)SW4 is turned on, the rectified power con be conducted to theelectronic device. The center tap of the transformer 30 is furtherelectrically connected to an output capacitor Co.

The function and relative description of other components of powerconversion system of this embodiment are the same as that of firstembodiment mentioned above and are not repeated here for brevity, andthe power conversion of this embodiment can achieve the functions as thepower conversion system of the first embodiment does.

Reference is made to FIG. 12, which is a circuit diagram of anintegrated power-converting module according to the present invention.The integrated power-converting module having functions of changingvoltage, rectification, and filtration, and includes a transformer 5, aplurality of rectifiers 44, and a plurality of filter 46. The rectifier44 and the filters 46 are electrically connected to a secondary side ofthe transformer 5. The rectifier 44 receives the converted electricpower outputted from the secondary side of the transformer 5 andconverts the converted electric power from alternative current (AC),which periodically reverse direction, to direct current (DC), which flowin only one direction. The filter 46 is configured to remove theunwanted AC components (or called ripple) of the rectifier 44 output,thus the integrated power-converting module can output a smooth andsteady DC.

Reference is made to FIG. 13 and FIG. 14, which are respectively anexploded view and an assembled view of the integrated power-convertingmodule according to the present invention. The integratedpower-converting module includes a bobbin 10′, at least one primary coil20, a magnetic core assembly 30′, and a plurality of power-convertingunits 41 a ^(˜) 41 d.

The bobbin 10′ includes a main body 100, a plurality of winding portions102, and a plurality of receiving portions 104 a ^(˜) 104 d. The mainbody 100 includes a first channel 101. The amount of the receivingportions 104 a ^(˜) 104 b is the same as that of the winding portions102. The receiving portions 104 a ^(˜) 104 d are arranged in a parallelmanner, and the winding portions 102 and the receiving portions 104 a^(˜) 104 d are arranged in a stagger manner.

The main body 100 further includes a second channel 109 communicatingwith the first channel 101 and substantially perpendicular thereto.

The bobbin 10′ of the present invention includes four receiving portions104 a ^(˜) 104 d arranged at two opposite sides of the second channel109. In particular, the receiving portions 104 a and 104 b are arrangedat one side of the second channel 109, and the receiving portions 104 cand 104 d are arranged at the other side thereof. The winding portions102 also arranged at the opposite sides of the second channel 109, andthe winding portions 102 and the receiving portions 104 a ^(˜) 104 d arearranged in staggered manner.

Each of the receiving portions 104 a ^(˜) 104 d including a slot 106communicating with the first channel 101 and a side-wall 110 disposedopposite to the power-converting units 41 a ^(˜) 41 d and enclose theslot 106.

Each of the receiving portions 104 a ^(˜) 104 d further includes twoprotrusions 105 arranged on the bottom and far away from each other. Anextending direction of the protrusions 105 is substantiallyperpendicular to the opening direction of the slots 106. Thepower-converting module further includes a plurality of electricallyconductive terminals 12 and a plurality of fixing members 13, theelectrically conductive terminals 12 are connected to the protrusions105 far away from the power-converting units 41 a ^(˜) 41 b, and thefixing members 13 are connected to the protrusions 105 close to thepower-converting units 41 a ^(˜) 41 d.

The primary coil 20 is electrically connected to the electricallyconductive terminals 12 and is wound on the winding portions 102 inS-shaped, and initial end of the primary coil 20 is connected to one ofthe electrically connective terminal 12, and a terminal end of theprimary coil 20 is connected to the other electrically connectedterminal 12, as shown in FIG. 14. The primary coil 20 is a primarywinding of the integrated power-converting module.

The main body 100 further includes a plurality of spacers 108 arrangedbetween the second channel 109 and the receiving portions 104 b and 104c close to the second channel 109 for spacing the second channel 109 andthe receiving portions 104 b and 104 c.

The magnetic core assembly 30′ is assembled with the bobbin 102 andpartially inserted into the first channel 101. The magnetic core 30′ canbe assembled by two E-shaped magnetic cores, and each magnetic coreincludes a central led 300 and two lateral legs 302 and 304 arranged attwo opposite sides of the central lag 300 and connected thereto. Whenthe magnetic core assembly 30′ is assembled with the bobbin 102, the topsurfaces of the lateral leg 302 and 304 are contacted with each other,the central leg 300 is received within the first channel 101, and an airgap 31 is formed between the top surface of the central legs 300 andwithin the second channel 109, as shown in FIG. 16, and then an effectof energy storage is achieved. It should be noted that if the primarycoil 20 does not wind on above the air gap 31, an eddy current loss canthen be effectively reduce.

Besides, when the magnetic core assembly 30′ is assembled with thebobbin 102, there are air passages 50 allowing vapor flowingtherethrough exist, and the air passages 50 are formed between thelateral lags 302 and 304 of each of the magnetic core and the main body100. Thus the integrated power-converting module has a good thermaldissipating effect.

The power-converting units 41 a ^(˜) 41 d are arranged in a parallelmanner and each of the power-converting units 41 a ^(˜) 41 d includes acircuit board 42, a rectifier 44, and a filter 46.

The circuit board 42 includes a base portion 420 and an extendingportion 422 connected to the base portion 420. The base portion 420 andthe extending portion 422 are both placed with copper foil, and anelectrically connected sheet 43 is placed on the extending portion 422and attached to the copper foil formed thereon, thus the electricallyconductive sheet 43, the rectifier 44, and the filter 46 can beelectrically connected to each other. As shown in the FIG. 13, a profileof the base portion 420 is substantially of rectangular, and a pluralityof connecting terminals 426 are connected to the bottom of each of thebase portions 420.

A penetrating hole 424 is formed on the extending portion 422 so that aprofile of the extending portion 422 is ring shape and corresponding tothat of the receiving portions 104 a ^(˜) 104 d, and when the extendingportions 422 are inserted into the receiving portions 104 a ^(˜) 104 d,the penetrating hole 424 of each extending portion 422 is aligned withand communicating with the first channel 101. The extending portions 422are configured to transit alternative current to the rectifiers 44.

The power-converting unit 41 a ^(˜) 41 d can further includes theelectrically conductive sheets 43 placed on each of the extendingportions 423 and attached on the copper foil. A profile of theelectrically conductive sheet 43 is corresponding to that of theextending portion 423 and has an opening 430, thus the electricallyconductive sheets 43 is of C-shaped. The electrically conductive sheets43 configured to conduct current can be made of tinned copper forproviding a good electrical conduction and thermal dissipation.

In the present invention, the primary coil 20 wound on the windingportion 102, the magnetic core assembly 30′ assembled with the bobbin10′, the extending portions 422 where placed with copper foil (and theelectrically conductive sheet 43) and inserted into the slots 106 of thebobbin 10′, collectively construct the transformer 5 shown in FIG. 12.

The rectifier 44 is placed on one surface of the base portion 420 of thecircuit boards 42, and the filter 46 is placed on the other surface ofthe base portion 420 thereof. The rectifier 44 can be synchronousrectifier composed of four metal-oxide-semiconductor field-effecttransistors (MOSFETs). Each of the power-converting units 41 a ^(˜) 41 dfurther includes a electrically conductive plate 48 placed on the baseportion 420, and the electrically conductive plate 48 and the rectifier44 are placed on the same surface. The filter 46 is, for example, choke.

The surface of the power-converting unit 41 b placed with the filter 46faces the surface of the power-converting unit 41 c placed with thefilter 46, which means that the filters 46 of the two power-convertingunits 41 b and 41 c close to the second channel 109 face each other, andthe length of two filters 46 aforementioned is substantially equal tothe width of the second channel 109.

Moreover, the surface of the circuit board 42 of the power-convertingunit 41 a placed with the rectifier 44 faces the surface of the circuitboard 42 of the power-converting unit 41 b placed with the rectifier 44.In the other words, two power-converting units 41 a and 41 b (or 41 cand 41 d) arranged at the same side of the second channel 109 face eachother. In such manner, the integrated power-converting module is compactsince the power-converting units 41 a ^(˜) 41 d are tightly arranged.

The integrated power-converting module of the present invention havingcircuit diagram shown in FIG. 12 and arrangement shown in FIG. 13 andFIG. 17, which has advantage of compact and eddy current loss andswitching loss can be effectively reduced.

The integrated power-converting module can be mounted on a circuit mainboard, in the other words, the circuit main board is disposed below theintegrated power-converting module. The fixing members 13 is insertedinto the circuit main board, so that the integrated power-convertingmodule can stand on the circuit main board to prevent the integratedpower-converting module from tilt caused by heavy weight. It should benoted that if the integrated power-converting module includes both thefixing members 13 and the electrically conductive terminals 12, theelectrically conductive terminals 12 can be disposed at the bottom ofthe receiving portions 104 a ^(˜) 104 d, and the primary coil 30′ can beconnected to the electrically connected terminals 12 and electricallyconnected to the circuit main board via the electrically connectedterminals 12. The fixing members 13 are disposed at the bottom of thereceiving portions 104 a ^(˜) 104 d where the electrically conductiveterminal is not disposed, such that the integrated power-convertingmodule can stand firmly on the circuit main board. If the integratedpower-converting module only includes the fixing members 13, the fixingmembers 13 are disposed at the bottom of the receiving portions 104 a^(˜) 104 d, and the primary coil 20 wound on the bobbin 10′ is directlyconnected to the circuit main board (by fly line connection). In thepractical application, the arrangement of the electrically connectiveterminals 12 and the mixing member 13 can be adjusted based on thedifferent situations.

The integrated power-converting module of the present invention foroutputting multiple direct current electric powers integrates secondarywindings (the copper foil or electrically conductive sheet 43 formed onthe extending portions 422), the rectifier 44, and the filter 46 intoone circuit board 42, which is assembled with the bobbin 10′ byinserting the extending portions 422 into the receiving portions 104 a^(˜) 104 d respectively. Thus it is compact and easily to manufactureand assemble.

As shown in FIG. 18, the power conversion system 1000 includes a printedcircuit board 1001, a switching module 1002, a resonance module 1003, avoltage conversion module 1004, and an output control device 1500. Asshown in FIG. 18, in structure, the resonant module 1003 is electricallyconnected between the switching module 1002 and the voltage conversionmodule 1004, and the voltage conversion module 1004 is electricallyconnected to the output control device 1500. For example, the switchingmodule 1002 may be the full bridge switching module 10 described above,the resonant module 1003 may be the resonant module 20 described above,and the voltage conversion module 1004 may be the isolation transformer30 described above, and the output control device 1500 may be theoutput-controlling device 40 as described above. The switching module1002, the resonant module 1003, the voltage conversion module 1004, andthe output control device 1500 may be disposed on the printed circuitboard 1001 or may be disposed on different printed circuit boardselectrically connected to each other. Those with ordinary skill in theart may flexibly design depending on the desired application.

Refer to FIG. 18 and FIG. 19, the voltage conversion module 1004includes a front side magneto-sensitive unit 1100, a first voltageconversion unit 1200, and a second voltage conversion unit 1300. Thefront-side magneto-sensitive unit 1100 is electrically connected theresonant module 1003, and the front-side magneto-sensitive unit 1100receives the electric energy transmitted from the resonant module 1003to generate a magnetic energy signal and isolatedly transmits themagnetic energy signal. The first voltage conversion unit 1200 and thefront side magneto-sensitive unit 1100 form a magnetic loop, and thefirst voltage conversion unit 1200 includes a first output portion 1213.The first output portion 1213 is inserted into the printed circuit board1001. The second voltage conversion unit 1300 and the front sidemagneto-sensitive unit 1100 form a magnetic loop, and the second voltageconversion unit 1300 includes a second output portion 1313. The secondoutput portion 1313 is inserted into the printed circuit board 1001. Thefirst voltage conversion unit 1200 and/or the second voltage conversionunit 1300 receive the magnetic energy signal transmitted from the frontside magneto-sensitive unit 1100 and process the magnetic energy signalinto an energy signal. The first output portion 1213 and the secondoutput portion 1313 conduct the processed energy signal to the printedcircuit board 1001.

The output control device 1500 includes a controller 1510, a firstoutput control switch 1511 and a second output control switch 1512. Thefirst output control switch 1511 is electrically connected to the firstoutput portion 1213, and the second output control switch 1512 iselectrically connected to the second output portion 1313. The outputcontrol device 1500 is mainly based on the energy demand of the loadside to control the first output control switch 1511 and the secondoutput control switch 1512, so as to supply the processed energy signalfrom the first voltage conversion unit 1200 and/or the second voltageconversion unit 1300 to the load side.

In use, the switching module 1002 is used to pass the positivehalf-cycle or negative half-cycle of the input AC, or to convert thepositive half-cycle or the negative half-cycle to another half-cycle, sothat all half cycles are positive half cycle or negative half-cycle, andthen output one-direction signal of all positive half-cycle or negativehalf-cycle. The resonant module 1003 is used to receive and process aone-direction signal, and output a first voltage.

The front side magneto-sensitive unit 1100 is used to receive the firstvoltage and generate magnetic energy. The first voltage conversion unit1200 and the front side magneto-sensitive unit 1100 form a magnetic loopto magnetize each other to produce a first induced current and rectifythe first induced current as a first current. The first output portion1213 is used to conduct the first current to the printed circuit board1001. The second voltage conversion unit 1300 and the front sidemagneto-sensitive unit 1100 form a magnetic loop to magnetize each otherto produce a second induced current and rectify the second inducedcurrent as a second current. The second output portion 1313 is used toconduct the second current to the printed circuit board 1001.

The controller 1510 controls the first output control switch 1511 to beturned on or off or the second output control switch 1512 to be turnedon or off. When the first output control switch 1511 is turned on andthe second output control switch 1512 is turned off, the first currentis outputted; when the first output control switch 1511 is turned offand the second output control switch 1512 is turned on, the secondcurrent is outputted; when the first output control switch 1511 and thesecond output control switch 1512 are all turned on, a third current isoutputted, where the third current is the sum of the first current andthe second current.

As shown in FIG. 19 and FIG. 20, the front side magneto-sensitive unit1100 has a first hollow portion 1101. For example, the front sidemagneto-sensitive unit 1100 may be a copper wire winding, a copper piecewinding, or a winding is formed by a copper foil of a printed circuitboard, but is not limited thereto, or may be a primary winding 310 asdescribed in FIG. 2 or FIG. 7.

The first voltage conversion unit 1200 includes a second hollow portion1214, and the second voltage conversion unit 1300 includes a thirdhollow portion 1314. The voltage conversion module 1004 further includesa core group 1400 having a centre leg 1410 installed in the secondhollow portion 1214, the third hollow portion 1314, and the first hollowportion 1101, as described above.

The bobbin 1110 is used to combine the front side magneto-sensitive unit1100, the first voltage conversion unit 1200, the second voltageconversion unit 1300, and the core group 1400 to form a voltageconversion module 1004. The bobbin 1110 has a containment space thathouses the front side magneto-sensitive unit 1100, the first voltageconversion unit 1200, and the second voltage conversion unit 1300. Thebobbin 1110 has a through hole 1111 for receiving the centre leg 1410.

As shown in FIG. 21 and FIG. 22, the first voltage conversion unit 1200includes a first conductive substrate 1210, a first rear side magneticsensitive layer 1220, a third rear side magnetic sensitive layer 1225,and a first rectifying unit 1230.

The first conductive substrate 1210 has a first conductive region 1212and a first output portion 1213, and two sides of the first conductivesubstrate 1210 have a first magnetic sensitive region 1211 and a thirdmagnetic sensitive region 1215, respectively. The first magneticsensitive region 1211 and the third magnetic sensitive region 1215 havea second hollow portion 1214. The first magnetic sensitive region 1211and the third magnetic sensitive region 1215 are connected to orelectrically connected to the first conductive region 1212. The firstconductive region 1212 and the first output portion 1213 are connectedor electrically connected.

The first rear side magnetic sensitive layer 1220 is arranged on thefirst magnetic sensitive region 1211 in an annular manner, and the firstrear side magnetic sensitive layer 1220 has a first open end 1221 and asecond open end 1222 that are not connected to each other. The thirdrear side magnetic sensitive layer 1225 is arranged on the thirdmagnetic sensitive region 1215 in an annular manner, and the third rearside magnetic sensitive layer 1225 has a third open end 1226 and afourth open end 1227 that are not connected to each other. The firstrear side magnetic sensitive layer 1220 is electrically connected to thethird rear side magnetic sensitive layer 1225 through the firstconductive substrate 1210. The first rear side magnetic sensitive layer1220 and third rear side magnetic sensitive layer 1225 for interactingwith the front side magneto-sensitive unit 1100 to produce a firstinduced current. In other words, the first rear side magnetic sensitivelayer 1220 of the first magnetic sensitive region 1211 and the thirdrear side magnetic sensitive layer 1225 of the third magnetic sensitiveregion 1215 receive the magnetic energy signal of the front sidemagneto-sensitive unit 1100 to generate an energy signal. The energysignal is conducted to the printed circuit board 1001 via the firstconductive region 1212 and the first output portion 1213.

The first rectifying unit 1230 is disposed on the first conductiveregion 1212 and is electrically connected to the first rear sidemagnetic sensitive layer 1220 and the third rear side magnetic sensitivelayer 1225, to rectify the first induced current to a first current. Thefirst output portion 1213 is electrically connected to the firstrectifying unit 1230, and the first output portion 1213 outputs thefirst current. A filter unit composed of an inductor L and/or acapacitor C may be provided between the first output portion 1213 andthe first rectifying unit 1230 to filter the first current. In oneembodiment of the present invention, the first rectifying unit 1230 maycomprise at least one switch for rectification in a switched manner.

The first magnetic sensitive region 1211 is provided with a metal sheet1610, and the metal sheet 1610 is bonded to the first rear side magneticsensitive layer 1220 to increase the heat dissipation and currenttolerance. The first magnetic sensitive region 1211 is provided with twofirst positioning holes 1701 which are diagonally to each other. Themetal sheet 1610 includes a positioning structure 1611 for engaging withthe first positioning hole 1701. For example, the positioning structure1611 may be a bump that is locally punched on the metal sheet 1610. Onthe other hand, a metal sheet 1620 is disposed on one side of the firstconductive region 1212, and the metal sheet 1620 serves to increase theheat dissipation and current resistance.

The third magnetic sensitive region 1215 is provided with a metal sheet1630, and the metal sheet 1630 is bonded to the third rear side magneticsensitive layer 1225 to increase the heat dissipation and currenttolerance. The third magnetic sensitive region 1215 is provided with twothird positioning holes 1703 which are diagonally to each other. Themetal sheet 1630 includes a positioning structure 1631 for engaging withthe third positioning hole 1703. For example, the positioning structure1631 may be a bump that is locally punched on the metal sheet 1630. Onthe other hand, a metal sheet 1640 is disposed on the other side of thefirst conductive region 1212 for increasing the heat dissipation andcurrent resistance. The first positioning hole 1701 and the thirdpositioning hole 1703 are offset from each other, where the two firstpositioning holes 1701 and the two third positioning holes 1703 arerespectively diagonally opposed to each other, so that the positioningstructure 1611 is engaged with the positioning structure 1631, and toenhance structural stability.

The first output portion 1213 is located in the first conductive region1212. It has a first angle Θ1 between the first magnetic sensitiveregion 1211 and the first output portion 1213, where the first angle Θ1is greater than 0 degrees and less than 180 degrees.

The structure and circuit characteristics of the second voltageconversion unit 1300 are substantially the same as those of the firstvoltage conversion unit 1200 and are not repeated herein. It isimportant to note that the first voltage conversion unit 1200 and thesecond voltage conversion unit 1300 may be identical or may be arrangedon opposing side of the mirror manner, or are individually separatecircuit layout designs, all of which fall within the scope of thepresent invention.

As shown in FIG. 23 and FIG. 24, the bobbin 1110 has a firstaccommodating part 2510, a second accommodating part 2520, and a firstopening 2521, wherein the second accommodating part 2520 has a secondopening 2522. The first opening 2521 and the second opening 2522 areconnected to each other, and the first opening 2521 is larger than thesecond opening 2522. In use, the first accommodating part 2510 is usedto accommodate the front side magneto-sensitive unit 1100, and thesecond accommodating part 2520 accommodates the first voltage conversionunit 1200 and/or the second voltage conversion unit 1300. And the secondaccommodating part 2520 improves heat dissipation via first opening 2521and the second opening 2522.

The upper and/or lower edges of the first opening 2521 have a stopper2523 against the first voltage conversion unit 1200 or the secondvoltage conversion unit 1300.

The upper and/or lower edges of the second opening 2522 have a stopper2524. The stopper 2524 of the upper and/or lower edge of the secondopening 2522 is disposed against the magnetic sensitive regions of thefirst voltage conversion unit 1200 or the second voltage conversion unit1300.

The upper and/or lower edges of the second accommodating part 2520 areprovided with divider blocks 2528 and 2529 which divide the secondaccommodating part 2520 into two slots 2525 and 2526. The two slots 2525and 2526 provide the first voltage conversion unit 1200 and the secondvoltage conversion unit 1300 to be inserted respectively.

Refer to FIG. 20 and FIG. 24, a first height T1 is between the upperedge of the through hole 1111 in FIG. 20 and the upper wall of thesecond accommodating part 2520. A second height T2 is between the loweredge of the through hole 1111 and the lower wall of the secondaccommodating part 2520. The divider block 2528 has a third height T3.The divider block 2529 has having a fourth height T4. The third heightT3 of the divider block 2528 is less than the first height T1 so as toprevent the divider block 2528 from penetrating through the through hole1111 and affecting the assembly of the core group 1400. The fourthheight T4 of the divider block 2529 is less than the second height T2,thereby preventing the divider block 2529 from penetrating through thethrough hole 1111 and affecting the assembly of the core group 1400.

The upper and/or lower edges of the first opening 2521 have a notch 2800for positioning or fixing the first voltage conversion unit 1200 and thesecond voltage conversion unit 1300.

As shown in FIG. 25 and FIG. 26, the front side magneto-sensitive unit1100, the first voltage conversion unit 1200 and the second voltageconversion unit 1300 are assembled together with the bobbin 1110. Thefront side magneto-sensitive unit 1100 is installed in the firstaccommodating part 2510, the first voltage conversion unit 1200 isinserted in the slot 2525 of the second accommodating part 2520, and thesecond voltage conversion unit 1300 is inserted in the slot 2526 of thesecond accommodating part 2520. A gap 2530 is formed between the firstvoltage conversion unit 1200 and the second voltage conversion unit1300. The stopper 2523 of the first opening 2521 is disposed against thefirst voltage conversion unit 1200 and the second voltage conversionunit 1300, and magnetic sensitive regions of the first magneticconversion unit 1200 and the second voltage conversion unit 1300 aredisposed against the stopper 2524 of the second opening 2522.

Referring to FIG. 27, there is a schematic cross-sectional view of theA-A′ section of the bobbin 1110 in FIG. 20, where the hatching line A-A′corresponds to the position where the second accommodating part 2520 islocated at the divider blocks 2528 and 2529. As shown in FIG. 27, afterthe centre leg 1410 penetrates the through hole 1111, it can block aportion of the gap 2530 (see FIG. 26), but since the first height T1 isgreater than the third height T3 and the second height T2 is greaterthan the fourth height T4. The upper edge of the through hole 1111 withthe lower edge of the divider block 2528, and the lower edge of thethrough hole 1111 with the upper edge of the divider block 2529 form theupper and lower passages, respectively. There is a distance between thesecond opening 2522 and an end of the through hole 1111 close to thesecond opening 2522, so that the air flow can flow between the firstopening 2521 and the second opening 2522 via the upper or lower passagesin the gap 2530 (see FIG. 26) to increase the heat dissipation effect.

It should be understood that although the above-described embodimentshave been described in terms of the first voltage conversion unit 1200and the second voltage conversion unit 1300, which are adjacent to theslots inserted into a space, but this does not limit the number of thevoltage conversion units of the present invention. In other embodimentsof the present invention, the voltage conversion unit 2200 isindividually inserted in the slot 2525 or slot 2526 of the secondaccommodating part 2520 of the bobbin 1110, as shown in FIG. 28 and FIG.29. Through this alone manner can also be used to achieve the same orsimilar efficacy.

In another embodiment of the present invention, as shown in FIG. 30 andFIG. 31, the voltage conversion module 3000 includes a front sidemagneto-sensitive unit 3100, a core group 3200, a bobbin 3300, and avoltage conversion unit 3400. The front side magneto-sensitive unit 3100receives the electric energy to generate a magnetic energy signal andisolatedly transmits the magnetic energy signal. The voltage conversionunit 3400 and the front side magneto-sensitive unit 3100 form a magneticloop, and the voltage conversion unit 3400 includes an output portion3420 inserted into the printed circuit board. The voltage conversionunit 3400 receives the magnetic energy signal sent by the front sidemagneto-sensitive unit 3100 and processes the magnetic energy signal asan energy signal. The output portion 3420 conducts the processed energysignal to the printed circuit board.

In use, the front side magneto-sensitive unit 3100 is used to receivethe voltage and generate magnetic energy. The voltage conversion unit3400 and the front side magneto-sensitive unit 3100 form a magnetic loopto magnetize each other to produce an induced current and rectify theinduced current as a rectified current. The output portion 3420 is usedto conduct the rectified current to the printed circuit board.

The front side magneto-sensitive unit 3100 has a first hollow portion3110. For example, the front side magneto-sensitive unit 3100 may be acopper wire winding, a copper piece winding, or a winding is formed bythe copper foil of a printed circuit board, but is not limited thereto,or may be a primary winding 310 as described in FIG. 2 or FIG. 7.

The voltage conversion unit 3400 includes a second hollow portion 3410.The core group 3200 having a centre leg 3210 installed in the secondhollow portion 3410, and the first hollow portion 3110 as describedabove.

The bobbin 3300 is used to combine the front side magneto-sensitive unit3100, the voltage conversion unit 3400, and the core group 3200 to forma voltage conversion module 3000. The bobbin 3300 has a containmentspace that houses the front side magneto-sensitive unit 3100 and thevoltage conversion unit 3400. The bobbin 3300 has a through hole 3340for receiving the centre leg 3210.

The structure and circuit characteristics of the voltage conversion unit3400 are substantially the same as those of the first voltage conversionunit 1200 and are not repeated herein.

As shown in FIG. 32 and FIG. 33, the bobbin 3300 has a firstaccommodating part 3310, a second accommodating part 3320, and a firstopening 3330, wherein the second accommodating part 3320 has a secondopening 3321. The first opening 3330 and the second opening 3321 areconnected to each other, and the first opening 3330 is larger than thesecond opening 3321. In use, the first accommodating part 3310 is usedto accommodate the front side magneto-sensitive unit 3100, and thesecond accommodating part 3320 accommodates the voltage conversion unit3400. The heat generated from the voltage conversion unit 3400 isdissipated via the first opening 3330 and the second opening 3321.

The upper and/or lower edges of the first opening 3330 have a stopper3331 against the voltage conversion unit 3400.

The upper and/or lower edges of the second opening 3321 have a stopper3323. The stopper 3323 of the upper and/or lower edge of the secondopening 3321 is disposed against the magnetic sensitive regions of thevoltage conversion unit 3400.

The second accommodating part 3320 has a slot 3322. The slot 3322provides the voltage conversion unit 3400 to be inserted therein.

The upper and/or lower edges of the first opening 3330 have a notch 3332for positioning or fixing the voltage conversion unit 3400.

As shown in FIG. 34 and FIG. 35, the front side magneto-sensitive unit3100, and the voltage conversion unit 3400 are assembled together withthe bobbin 3300. The front side magneto-sensitive unit 3100 is installedin the first accommodating part 3310, and the voltage conversion unit3400 is inserted in the slot 3322 of the second accommodating part 3320.Wherein the stopper 3331 of the first opening 3330 is disposed againstthe voltage conversion unit 3400, and the magnetic sensitive region ofvoltage conversion unit 3400 is disposed against the stopper 3323 of thesecond opening 3321.

When the voltage conversion unit 3400 is inserted into the slot 3322, agap 3324 is formed between the inner wall of the second accommodatingpart 3320 and the voltage conversion unit 3400. See FIG. 36, which is aschematic view of the A-A′ section of the bobbin 3300 in FIG. 31. InFIG. 35 and FIG. 36, after the centre leg 3210 penetrates the throughhole 3340, it can partially block the gap 3324, but the gap 3324 is notcompletely blocked by the centre leg 3210. There is a distance betweenthe second opening 3321 and an end of the through hole 3340 close to thesecond opening 3321, so that the air flow can flow between the firstopening 3330 and the second opening 3321 via the gap 3324 to increasethe heat dissipation effect.

In another embodiment of the present invention, as shown in FIG. 37 andFIG. 38, the voltage conversion module 5000 includes a front sidemagneto-sensitive unit 5100, a core group 5200, a bobbin 5300, a firstvoltage conversion unit 5400, a second voltage conversion unit 5500, athird voltage conversion unit 5600 and a fourth voltage conversion unit5700. The core group 5200 has a centre leg 5210. The front sidemagneto-sensitive unit 5100 receives the electric energy to generate amagnetic energy signal and isolatedly transmits the magnetic energysignal. The first voltage conversion unit 5400 and the front sidemagneto-sensitive unit 5100 form a magnetic loop, and the first voltageconversion unit 5400 includes a first output portion 5430 inserted intothe printed circuit board. The second voltage conversion unit 5500 andthe front side magneto-sensitive unit 5100 form a magnetic loop, and thesecond voltage conversion unit 5500 includes a second output portion5530 inserted into the printed circuit board. The third voltageconversion unit 5600 and the front side magneto-sensitive unit 5100 forma magnetic loop, and the third voltage conversion unit 5600 includes athird output portion 5630 inserted into the printed circuit board. Thefourth voltage conversion unit 5700 and the front side magneto-sensitiveunit 5100 form a magnetic loop, and the third voltage conversion unit5600 includes a fourth output portion 5730 inserted into the printedcircuit board. The first voltage conversion unit 5400, the secondvoltage conversion unit 5500, the third voltage conversion unit 5600and/or the fourth voltage conversion unit 5700 receives the magneticenergy signal sent by the front side magneto-sensitive unit 5100 andprocesses the magnetic energy signal as an energy signal. The firstoutput portion 5430, the second output portion 5530, the third outputportion 5630, and the fourth output portion 5730 conduct the processedenergy signal to the printed circuit board.

In use, the front side magneto-sensitive unit 5100 is used to receivethe voltage and generate magnetic energy. The first voltage conversionunit 5400, the second voltage conversion unit 5500, the third voltageconversion unit 5600, the fourth voltage conversion unit 5700 and thefront side magneto-sensitive unit 5100 form a magnetic loop to magnetizeeach other to produce a induced current and rectify the induced currentas a rectified current. The first output portion 5430, the second outputportion 5530, the third output portion 5630, and the fourth outputportion 5730 are used to conduct the rectified current to the printedcircuit board.

The front side magneto-sensitive unit 5100 has a first hollow portion5110. For example, the front side magneto-sensitive unit 5100 may be acopper wire winding, a copper piece winding, or a winding is formed by acopper foil of a printed circuit board, but is not limited thereto, ormay be a primary winding 310 as described in FIG. 2 or FIG. 7.

The first voltage conversion unit 5400 includes a second hollow portion5411. The second voltage conversion unit 5500 includes a third hollowportion 5511. The third voltage conversion unit 5600 includes a fourthhollow portion 5611. The fourth voltage conversion unit 5700 includes afifth hollow portion 5711. The core group 5200 having a centre leg 5210installed in the second hollow portion 5411, the third hollow portion5511, the fourth hollow portion 5611, the fifth hollow portion 5711, andthe first hollow portion 5110 as described above.

The bobbin 5300 is used to combine the front side magneto-sensitive unit5100, the first voltage conversion unit 5400, the second voltageconversion unit 5500, the third voltage conversion unit 5600, the fourthvoltage conversion unit 5700 and the core group 5200 to form a voltageconversion module 5000. The bobbin 5300 has a containment space thathouses front side magneto-sensitive unit 5100, the first voltageconversion unit 5400, the second voltage conversion unit 5500, the thirdvoltage conversion unit 5600 and the fourth voltage conversion unit5700. The bobbin 5300 has a through hole 5340 for receiving the centreleg 5210.

The structure and circuit characteristics of the first voltageconversion unit 5400, the second voltage conversion unit 5500, the thirdvoltage conversion unit 5600 and the fourth voltage conversion unit 5700are substantially the same as those of the first voltage conversion unit1200 and are not repeated herein. It is important to note that the firstvoltage conversion unit 5400, the second voltage conversion unit 5500,the third voltage conversion unit 5600 and the fourth voltage conversionunit 5700 may be identical or may be arranged on opposing side of themirror manner, or are individually separate circuit layout designs, allof which fall within the scope of the present invention.

As shown in FIG. 39 and FIG. 40, the bobbin 5300 has a firstaccommodating part 5310, a second accommodating part 5320, and a thirdaccommodating part 5330. The second accommodating part 5320 has a firstopening 5321 and a second opening 5322. The first opening 5321 and thesecond opening 5322 are connected to each other, and the first opening5321 is larger than the second opening 5322. The third accommodatingpart 5330 has a third opening 5331 and a fourth opening 5332. The thirdopening 5331 and the fourth opening 5332 are connected to each other,and the third opening 5331 is larger than the fourth opening 5332. Inuse, the first accommodating part 5310 is used to accommodate the frontside magneto-sensitive unit 5100, and the second accommodating part 5320accommodates the first voltage conversion unit 5400 and/or the secondvoltage conversion unit 5500. And the second accommodating part 5320improves heat dissipation via the first opening 5321 and the secondopening 5322. The third accommodating part 5330 accommodates the thirdvoltage conversion unit 5600 and/or the fourth voltage conversion unit5700. And the third accommodating part 5330 improves heat dissipationvia the third opening 5331 and the fourth opening 5332.

The upper and/or lower walls of the first opening 5321 have dividerblocks 5323 and 5324 which divide the second accommodating part 5320into two slots 5325 and 5326. The two slots 5325 and 5326 provide thefirst voltage conversion unit 5400 and the second voltage conversionunit 5500 to be inserted respectively.

The upper and/or lower walls of the third opening 5331 have dividerblocks 5333 and 5334 which divide the third accommodating part 5330 intotwo slots 5335 and 5336. The two slots 5335 and 5336 provide the thirdvoltage conversion unit 5600 and the fourth voltage conversion unit 5700to be inserted respectively.

The upper and/or lower edges of the first opening 5321 have a stopper5327 against the first voltage conversion unit 5400 and/or the secondvoltage conversion unit 5500.

The upper and/or lower edges of the second opening 5322 have a stopper5328 against the first voltage conversion unit 5400 and/or the secondvoltage conversion unit 5500.

The upper and/or lower edges of the third opening 5331 have a stopper5337 against the third voltage conversion unit 5600 and/or the fourthvoltage conversion unit 5700.

The upper and/or lower edges of the fourth opening 5332 have a stopper5338 against the third voltage conversion unit 5600 and/or the fourthvoltage conversion unit 5700.

Refer to FIG. 38 and FIG. 40, a first height T1 is between the upperedge of the through hole 5340 in FIG. 40 and the upper wall of thesecond accommodating part 5320. A second height T2 is between the loweredge of the through hole 5340 and the lower wall of the secondaccommodating part 5320. The divider block 5323 has a third height T3.The divider block 5324 has having a fourth height T4. The third heightT3 of the divider block 5323 is less than the first height T1 so as toprevent the divider block 5323 from penetrating through the through hole5340 and affecting the assembly of the core group 5200. The fourthheight T4 of the divider block 5324 is less than the second height T2,thereby preventing the divider block 5324 from penetrating through thethrough hole 5340 and affecting the assembly of the core group 5200.

The upper and/or lower edges of the first opening 5321 and the thirdopening 5331 have notches 5350 for positioning or fixing the firstvoltage conversion unit 5400, the second voltage conversion unit 5500,the third voltage conversion unit 5600 and the fourth voltage conversionunit 5700.

As shown in FIG. 41 and FIG. 42, the front side magneto-sensitive unit5100, the first voltage conversion unit 5400, the second voltageconversion unit 5500, the third voltage conversion unit 5600 and thefourth voltage conversion unit 5700 are assembled together with thebobbin 5300. The front side magneto-sensitive unit 5100 is installed inthe first accommodating part 5310. The first voltage conversion unit5400 and the second voltage conversion unit 5500 are inserted in theslots 5325 and 5326 of the second accommodating part 5320. A gap 5329 isformed between the first voltage conversion unit 5400 and the secondvoltage conversion unit 5500. The third voltage conversion unit 5600 andthe fourth voltage conversion unit 5700 are inserted in the slots 5335and 5336 of the third accommodating part 5330. A gap 5339 is formedbetween the third voltage conversion unit 5600 and the fourth voltageconversion unit 5700. The stopper 5327 of the first opening 5321 isdisposed against the first voltage conversion unit 5400 and the secondvoltage conversion unit 5500, and magnetic sensitive regions of thefirst voltage conversion unit 5400 and the second voltage conversionunit 5500 are disposed against the stopper 5328 of the second opening5322. The stopper 5337 of the third opening 5331 is disposed against thethird voltage conversion unit 5600 and the fourth voltage conversionunit 5700, and magnetic sensitive regions of the third voltageconversion unit 5600 and the fourth voltage conversion unit 5700 aredisposed against the stopper 5338 of the fourth opening 5332.

Referring to FIG. 43, there is a schematic cross-sectional view of theA-A′ section of the bobbin 5300 in FIG. 38, where the hatching line A-A′corresponds to the position where the second accommodating part 5320 islocated at the divider blocks 5323 and 5324. As shown in FIG. 43, afterthe centre leg 5210 penetrates the through hole 5340, it can block aportion of the gap 5329, but since the first height T1 is greater thanthe third height T3 and the second height T2 is greater than the fourthheight T4, the upper edge of the through hole 5340 with the lower edgeof the divider block 5323 and the lower edge of the through hole 5340with the upper edge of the divider block 5324 form the upper and lowerpassages, respectively. There is a distance between the second opening5322 and an end of the through hole 5340 close to the second opening5322, so that the air flow can flow between the first opening 5321 andthe second opening 5322 via the upper or lower passages in the gap 5329to increase the heat dissipation effect.

In the present embodiment, the structure of the third accommodating part5330 is substantially similar to that of the second accommodative part5320. After the centre leg 5210 penetrates the through hole 5340, theair flow can flow between the third opening 5331 and the fourth opening5332 via the upper or lower passages in the gap 5339 to increase theheat dissipation effect.

It should be noted that the embodiments of the present invention can becombined with different amounts of voltage conversion units depending onthe different requirements such as space, environment of use, outputpower, or so forth. For example, one voltage conversion unit is placedin a single accommodating space, three or four voltage conversion unitsare placed in two accommodating spaces, or more voltage conversion unitsare placed in more accommodating spaces. Those with ordinary skill inthe art may flexibly design depending on the desired application.

It will be apparent to those skilled in the art that variousmodifications and variations can be made to the structure of the presentinvention without departing from the scope or spirit of the invention.In view of the foregoing, it is intended that the present inventioncover modifications and variations of this invention provided they fallwithin the scope of the following claims.

What is claimed is:
 1. A voltage conversion module comprising: a frontside magneto-sensitive unit; at least one voltage conversion unit; acore group; and a bobbin comprising: a first accommodating part foraccommodating the front side magneto-sensitive unit; a secondaccommodating part for accommodating the at least one voltage conversionunit, wherein the second accommodating part comprises: a first openingdisposed at one side of the second accommodating part; and a secondopening disposed at another side of the second accommodating part; and athrough hole for accommodating the core group; wherein, the firstopening and the second opening are disposed opposite to each other, anda heat dissipation channel is formed between the first opening, thesecond opening and the at least one voltage conversion unit.
 2. Thevoltage conversion module of claim 1, wherein at least one of an upperedge and a lower edge of the first opening has a stopper against the atleast one voltage conversion unit, or at least one of an upper edge anda lower edge of the second opening has a stopper against the at leastone voltage conversion unit.
 3. The voltage conversion module of claim1, wherein a divider block is disposed on an upper edge and/or a loweredge of the second accommodating part, the divider block divides thesecond accommodating part into a plurality of slots, and the pluralityof slots are configured to accommodate the at least one voltageconversion unit.
 4. The voltage conversion module of claim 3, wherein anumber of the at least one voltage conversion unit is at least two,wherein the plurality of slots are configured to accommodate the atleast two voltage conversion units, and an interspace is formed betweenthe at least two voltage conversion units.
 5. The voltage conversionmodule of claim 3, wherein a distance between an upper edge of thethrough hole and the upper edge of the second accommodating part and adistance between an lower edge of the through hole and the lower edge ofthe second accommodating part are larger than a length of the dividerblock.
 6. The voltage conversion module of claim 3, wherein when the atleast one voltage conversion unit is disposed in the slot, an interspaceis formed between an inner wall of the second accommodating part and theat least one voltage conversion unit.
 7. The voltage conversion moduleof claim 3, wherein when the core group is disposed in the through hole,a side edge of the divider block and an upper edge or a lower edge ofthe through hole form an upper channel or a lower channel.
 8. Thevoltage conversion module of claim 1, wherein when the core group isdisposed in the through hole, an interspace is formed between the secondopening and an end of the through hole which is adjacent to the secondopening.
 9. The voltage conversion module of claim 1, wherein at leastone of an upper edge and a lower edge of the first opening has a notch,when the at least one voltage conversion unit is disposed in the slot,the at least one voltage conversion unit is embedded into the notch forlocating or fixing.
 10. A voltage conversion module comprising: a frontside magneto-sensitive unit; a voltage conversion unit having: a circuitboard having a base portion and an expending portion connected to thebase portion, wherein a penetrating hole is formed on the expendingportion, and a magnetic sensitive layer is disposed on the expendingportion for interacting with the front side magneto-sensitive unit; arectifier disposed on the base portion; and a filter disposed on thebase portion, wherein the filter and the rectifier are electricallyconnected; a core group; and a bobbin comprising: an accommodating partcomprising: a first opening disposed at one side of the accommodatingpart; and a second opening disposed at another side of the accommodatingpart; a spacer, wherein a winding part is formed between the spacer andthe accommodating part; and a through channel, wherein the throughchannel penetrates the accommodating part and the spacer; wherein, thefront side magneto-sensitive unit and the voltage conversion unit areaccommodated in the bobbin and part of the core group penetrates thethrough channel and the penetrating hole.
 11. The voltage conversionmodule of claim 10, wherein the first opening and the second opening aredisposed opposite to each other, wherein a heat dissipation channel isformed between the first opening, the second opening and the voltageconversion unit, and at least one of an upper edge and a lower edge ofthe first opening has a stopper against the expending portion or atleast one of an upper edge and a lower edge of the second opening has astopper against the expending portion.
 12. The voltage conversion moduleof claim 10, wherein an angle is formed between the base portion and theexpending portion, wherein a value of the angle is higher than 0 degreeand lower than 180 degrees.
 13. The voltage conversion module of claim10, wherein a metal sheet is disposed on the magnetic sensitive layer orthe expending portion for increasing a heat dissipation and currentresistance of the magnetic sensitive layer or the expending portion. 14.The voltage conversion module of claim 10, wherein a divider block isdisposed on an upper edge and/or a lower edge of the accommodating part,the divider block divides the accommodating part into a plurality ofslots, and the plurality of slots are configured to accommodate thevoltage conversion unit.
 15. The voltage conversion module of claim 14,wherein a distance between an upper edge of the through channel and theupper edge of the accommodating part and a distance between a lower edgeof the through channel and the lower edge of the accommodating part arelarger than a length of the divider block, and a side edge of thedivider block and the upper edge or the lower edge of the throughchannel form an upper channel or a lower channel.
 16. A bobbincomprising: an accommodating part comprising: a first opening disposedat one side of the accommodating part; and a second opening disposed atanother side of the accommodating part; a spacer, wherein a winding partis formed between the spacer and the accommodating part; and a throughchannel, wherein the through channel penetrates the accommodating partand the spacer; wherein, the first opening and the second opening aredisposed opposite to each other, and a heat dissipation channel isformed between the first opening, the second opening and an inner wallof the accommodating part.
 17. The bobbin of claim 16, wherein at leastone of an upper edge and a lower edge of the first opening has astopper, or at least one of an upper edge and a lower edge of the secondopening has a stopper.
 18. The bobbin of claim 16, wherein a dividerblock is disposed on an upper edge and/or a lower edge of theaccommodating part, and the divider block divides the accommodating partinto a plurality of slots.
 19. The bobbin of claim 18, wherein adistance between a upper edge of the through channel and the upper edgeof the accommodating part and a distance between a lower edge of thethrough channel and the lower edge of the accommodating part are largerthan a length of the divider block, and a side edge of the divider blockand the upper edge or the lower edge of the through channel form anupper channel or a lower channel.
 20. The bobbin of claim 16, wherein atleast one of an upper edge and a lower edge of the first opening has anotch.